Pile carpet



1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET l8 Sheets-Sheet 1 Original Filed July 19, 1950 INVENTOR PM: W. 5. #0656! an)? M TTORNEYS Aug. 2, 1955 F. w. E. HOESELBARTH 2,714,405

FILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 3 r INVENTOR PM: fifty/05:61am? n/ Aug. 2, 1955 F. w. E. HOESELBARTH PILE CARPET l8 Sheets-Sheet 4 Original Filed July 19, 1950 INVENTOR Fwvz ME #05:: an m Aug. 2, 195 F. w. E. HOESELBARTH 2,714,405

FILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 5 2, 1955 F. w. E. HOESELBARTH 2,714,405

FILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 6 ll Ni M J h INVENTOR F/wwz MET/195554 am? 71/ 1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET Original Filed July 19, 1950 l8 Sheets-Sheet 7 INVENTOR FRANZ WE. #d'JELBA/PT/l 8 1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET 18 Sheets-Sheet 8 Original Filed July 19. 1950 Aug. 2, 1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 9 INVENTOR FRANZ WE. #0555! 8/7)? 7' fl Aug. 1955 F. w. E. HOESELBARTH 2,714,405

FILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 10 -TTORNEYS FILE CARPET l8 Sheets-Sheet 11 Original Filed July 19, 1950 INVENTOR FKAA/Z WE 19015551 5A5 77/ ATTORNEYS Aug. 2, 1955 F. w. E. HOESELBARTH FILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 12 INVENTOR FRANZ NE. H0SEL BAR TH ATTORN EYS Aug. 2, 1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET Original Filed July 19, 1950 1a Sheets-Sheet 1s INVENTOR FK/MIZ W5 #06321 514/? TH Aug. 2, 1955 F. w. E. HOESELBARTH 2,714,405

' PILE CARPET Original Filed July 19, 1950 18 Sheets-Sheet 14 INVENTOR F/MA/ Z W- E. IIOESEL BA Aug. 1955 F. w. E. HOESELBARTH 2,714,405

FILE CARPET l8 Sheets-Sheet 15 Original Filed July 19. 1950 O A w my J r w Z M m F. w. E. HOESELBARTH 2,714,405

Aug. 2, 1955 PILE CARPET l8 Sheets-Sheet 16 Original Filed July 19 1950 INVENTOR HOESEL 5/? TH TTORNEYS FRANZ W E.

1955 F. w. E. HOESELBARTH 2,714,405

PILE CARPET Original Filed July 19. 1950 18 Sheets-Sheet 17 E v W g id Aug. 2, 1955 F. W. E. HOESELBARTH FILE CARPET l8 Sheets-Sheet 18 Original Filed July 19. 1950 INVENTOR r/w/z m5. 1/0551 aAm-H ITTORNEYS United States Patent PILE CARPET Frank W. E. Hoeselbarth, Carlisle, Pa., assignor to C. H. Maslantl & Sons, a corporation Original application June 19, 1950, Serial No. 168,960. Divided and this application November 19, 1951, Serial No. 257,006

7 Claims. (Cl. 139-403) The present invention relates to pile carpets which exhibit a plurality of levels of pile in the face, and to methods of weaving the same.

This application is a division of my U. S. application Serial No. 168,960, filed June 19, 1950, for Process of Weaving.

A purpose of the present invention is to produce a pile carpet having in different transverse rows of the same pile warp, wavy uncut pile loops and wavy cut pile tufts, desirably alternating with one another, with or without intervening pile projections of another pile warp.

A further purpose is to weave a alternately to the same pile warp, a straight non-cutting wire and a wavy wire having a cutter at the far end, weaving with a closeness of weave in excess of seven Wires per inch and preferably between seven and twelve wires per inch, more desirably between eight and ten wires per inch and most desirably between nine and ten wires per inch, whereby when the wavy wire is withdrawn, the required extra pile yarn to permit the high points of the wavy wire to be withdrawn will be only partly supplied by pulling down on the loops formed over the straight wire, and will partially be obtained by springing the yarn and fabric, and after the pile projections are cut by the wavy wire, the spring-back in the yarn and fabric will selectively pull down the tufts formed over the wavy wire and create a wavy effect in such tufts.

A further purpose is to restrict the extent to which the withdrawal of the wavy wire can pull down the adjoining straight wire loops so as to create spring-back which will produce waviness in the wavy wire pile projections.

A further purpose is to produce the alternating wavy transverse rows of cut and uncut pile projections in accordance with the invention in single pile warp velvet carpets, multiple pile warp velvet carpets and Wilton carpets as desired.

A further purpose is to employ straight non-cutting pile carpet, applying wires which are the same height as the maximum heights of the waves on the wavy wires, so that the maximum heights of the waves on the cut and uncut pile will be the same, and at points across the weave the cut pile tufts will at least partially mask the low wavy portions of the uncut loops, thus effectively blanking out the low uncut loops.

A further purpose is to displace the high points of the waves of the successive wavy wires and correspondingly of the successive pairs of wavy tufts and loops laterally with respect to one another to produce a pattern effect.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate a few only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory opera- Cit 2,714,405 Patented Aug. 2, 1955 tion and clear demonstration of the principles involved.

Figures 1 to 4 are weave step diagrams showing the successive steps of weaving a velvet pile carpet in accordance with the invention, using a single pile warp. The warps are in the plane of the paper.

Figure 5 is a fragmentary perspective of a wire set repeat which may be employed in various weaves of the present invention, the high points of the waves of the wavy wire being at a different height from the straight wire.

Figures 6 to 9 are wire-withdrawal weave diagrams of a weave in accordance with Figures 1 to 4, using wires corresponding to Figure 5 except that the high points of the waves of the wavy wire equal the height of the straight wire, and showing in longitudinal (warpwise) section the steps of withdrawing the two diiferent wires.

Figure 10 is a conventional longitudinal or warpwise section of a completed carpet in accordance with Figures 1 to 4 and Figures 6 to 9.

Figures 11 and 12 are top plan wire diagrams showing the distributions of the high points .on the wavy wires laterally across the wire set.

Figure 13 is a fragmentary section of a wavy wire employed in the invention, showing the contour of the wave.

Figure 14 is a face view of a single pile warp velvet carpet conforming to the weave of Figures 1 to 4, and 6 to 9 and 10 and embodying the principles of the invention. This may be regarded as the preferred embodiment.

Figure 15 is a face view of a single pile warp velvet carpet similar to Figure 14, except that the number of wires per inch was less than 7, and the wave in the cut tufts which is very desirable in the present invention is not exhibited. All other conditions are the same in Figures 14 and 15.

Figures 16 to 19 inclusive are views corresponding to Figures 1 to 4 except that two pile warps are used and in accordance with the velvet carpet system.

Figure 20 is a view corresponding to Figure 6, but showing the effect of using two difierent pile warps as in Figures 16 to 19.

Figure 21 is a view of the weave of Figures 16 to 19, but corresponding to Figure 9.

Figure 22 is a longitudinal fabric sectional diagram corresponding to Figure 10, but showing a weave of Figures 16 to 19.

Figures 23 to 26 are weave step diagrams corresponding to Figures 1 to 4, but showing a Wilton weave applied to the invention.

Figure 27 is a longitudinal sectional view corresponding to Figure 6, but showing the Wilton weave of Figures 23 to 26.

Figure 28 is a View corresponding to Figure 9, but showing the Wilton weave applied to the invention, at a point where pattern change does not occur.

Figure 29 is a view similar to Figure 28 except that it shows a point of pattern change.

Figure 30 is a view corresponding to Figure 10, but showing the Wilton weave applied to the invention.

In the drawings like numerals refer to like parts.

In C. H. Masland 2nd, U. S. patent application Serial No. 144,764, filed February 17, 1950, now abandoned, for Weaving With Effect From Orientation of High and Low Pile, disclosure is made of weaving carpet with alternate non-cutting straight wires and cutting wavy wires over which the same pile warp is raised. In accordance with the Masland invention, it is disclosed that when a wire set is employed, using alternate straight wires and wavy wires, when the wavy wire is withdrawn from the fabric it tends to pull down the pile projections formed over the straight wire, producing wavy pile projections, and raising the pile projections formed over the wavy wire until they achieve the height of the tops of the waves of the wavy wire. Thus in a loose weave, the result is to form wavy pile projections over the straight wire (by robbing from the pile projections formed over the straight wire after that wire is withdrawn) and to form straight pile projections over the wavy wire (by raising such pile projections to the maximum height of the waves when the wavy wire is withdrawn).

I have discovered that this effect, however, can be advantageously modified when a very tight weave is employed. In this case the tightness of the weave restricts the extent to which the wavy wire during withdrawal can rob pile from the pile projections formed over the straight wire, and while to some extent the pile required to permit withdrawal of the wavy wire is robbed from the pile projections produced over the straight wire, a substantial amount of pile required topermit withdrawal of the wavy wire is obtained by stretching the pile yarn and distorting or springing the back of the fabric on both sides of the wavy wire. The extent of the stretching the pile yarn and distortion or springing of the back of the fabric depends upon whether the particular pile projection is located at an initial low point or high point on the wavy wire, there being a great deal of stretching and distortion or springing at initial low points on the wavy wire and very little or no stretching and distortion or springing at initial high points on the wavy wire. After the wavy wire has been withdrawn, the pile projections at points where the pile yarn has been stretched and the back of the fabric has been distorted or sprung are pulled down or sprung back to an extent depending upon the extent of stretching, distortion or springing, thus producing wavy pile projections over the wavy wire, and creating a very novel effect.

Thus in accordance with the present invention, when I weave the same pile warp alternately over a straight non-cutting pilewire and a wavy pile wire having a cutter at the far end (remote from the head) I produce a transverse row of wavy uncut pile projections and a transverse row of wavy cut pile projections alternating on the same warp. Where other warps are employed, as in a Wilton weave or in a special multiple velvet weave as later explained, the cut warp or warps can exhibit the same effect or some other effect such as low pile, cutting or non-cutting, or a high pile, cutting or non-cutting, straight or wavy.

The most convenient manner of restricting the pulldown of the loops formed over the straight wire when the wavy wire is withdrawn, and thus causing springback to impart a wave to the pile tufts formed over the wavy wire is by increasing the closeness of the weave. This can be done very eifectively by increasing the number of wires per inch to in excess of seven, and preferably less than twelve, more desirably between eight and ten wires per inch, and most desirably between nine and ten wires per inch. Closeness of weave can also be increased by increasing the number of ends per inch in the warp with a view to causing springback and waviness in the warp. The efiect of the invention can be enhanced or varied by varying bulkiness of the pile yarn, adjusting tension of the binder warps, stuffer warps, pile warps and weft, varying the elasticity and thickness of the pile warp ends, and wefts, varying the construction of the carpet, and varying the heights of the wires and the heights of the tops and bottoms of the waves on the wavy wires.

For practical purposes, using any conventional weaving set-up it will be suflicient to keep the number of wires per inch between seven and twelve, in order to get the effect described herein, the pull-down on the uncut loops decreasing and the wave of the cut tufts increasing as the number of wires per inch increases within this range.

These ranges of wires per inch will cause the effect of the invention by restricting pull-down of the loops formed over the straight non-cutting wire by the wavy cutting Wires per inch Pile yarn Dents per 27 (Pitch) gl gg ggggf (yards per tion ounce} 10 to 12 42 or heavier. or heavier. or heavier. or heavier. or heavier.

It will of course be evident that the pile yarn should not be thick enough to prevent weaving by causing excessive crowding as well known in the art. The following table lists for a pitch of 200 dents per 27 inches on a velvet carpet weave of the construction shown in Figure 10, the approximate limits of pile yarn thickness which i are usually practical from the standpoint of crowding for the various wire densities.

Limit of thickness of pile yarn in yards per ounce Wires per Inch The effect in accordance with the invention is enhanced by employing high points on the successive wavy wires which are laterally out of phase with one another according to some pattern or other arrangement.

Where the top of the wave of the wavy wire is at substantially the same height as the straight wire, the novel effect of the invention is further enhanced by providing points along the transverse rows where the wavy cut pile tufts partially or wholly mask the low wavy uncut pile loops, creating an additional interesting effect on the face of the fabric.

The invention is applicable to single pile velvet carpet weaves (including tapestry), multiple pile velvet carpet weaves (including tapestry) and Wilton weaves, as well as other pile carpet weaves. The invention can be applied to one or any or all of the pile warps where a plurality of pile warps are employed. Where it is applied to one of several-pile warps, there may be transverse rows of pile projections of other characters between the alternate uncut wavy pile loops and cut wavy pile tufts.

The present invention constitutes a simple and practical way to impart a wavy effect to alternate cut and uncut pile rows, overcoming the diificulty of the prior art in this direction.

Considering Figures 1 to 4 inclusive, these figures show diagrammatically the four steps of the cycle of a velvet carpet weave by which the process of the invention can be carried out and the weave of the invention can be produced. These figures illustrate a pile warp 40 manipulated by a pile warp heddle 41 and withdrawing pile from a pile warp beam 42 over a whip roll 43. It will be evident that through the present disclosure any tensioning device is conveniently designated as a whip roll, whether it usually be called a whip roll or a jumbo in current practice.

Stuffer warp 44 is withdrawn from stuffer warp beam 45 over whip roll 46. The stutter warp is manipulated by stuffer Warp heddle 47. It will be evident that if desired the usual practice can be followed of manipulating the stufier warp by a long slot in the heddle whose eyes carry the pile warp. 

